AUTOMATION:

Document By
SANTOSH BHARADWAJ REDDY
Email: help@matlabcodes.com
Engineeringpapers.blogspot.com
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Automation is the use of control systems such as computers to control industrial machinery and
processes, replacing human operators. In the scope of industrialization, it is a step beyond mechanization.
Whereas mechanization provided human operators with machinery to assist them with the physical
requirements of work, automation greatly reduces the need for human sensory and mental requirements as
well.

ADVANTAGES OF AUTOMATION:

The purpose of automation has shifted from increasing productivity and reducing costs, to broader
issues, such as increasing quality and flexibility in the manufacturing process.

Automation is now often applied primarily to increase quality in the manufacturing process, where
automation can increase quality substantially.

For example, automobile and truck pistons used to be installed into engines manually. This is
rapidly being transitioned to automated machine installation, because the error rate for manual installment
was around 1-1.5%, but has been reduced to 0.00001% with automation.

Hazardous operations, such as oil refining, the manufacturing of industrial chemicals, and all forms
of metal working, were always early contenders for automation.

Application of Automation
Power generation

TRANSMISSION AND DISTRIBUTION:

Oil and gas industries

Process industries
Building automation

HISTORY OF AUTOMATION
MANUAL CONTROL

HARDWIRED CONTROL:
Prior to PLCs, many of these control tasks were solved with contactor or relay controls. This is
often referred to as hard-wired control. Circuit diagrams had to be designed, electrical components specified
and installed, and wiring lists created. Electricians would then wire the components necessary to perform a
specific task. If an error was made the wires had to be reconnected correctly. A change in function or system
expansion required extensive component changes and rewiring.
DRAWBACKS:
Bulky and complex wiring.
Difficult to change the logic.
Unreliable.

RELAY :

RELAY LOGIC – AND GATE:

ELECTRONICS CONTROL
Logic gates and Electronic Circuits are used
Ease of programming
Ease of maintenance
Drawbacks:
Difficult to Troubleshoot while Change the Logic of the Process
Difficult to expand
Not suitable for industrial conditions

PROGRAMMABLE LOGICAL CONTORL

What is a Programmable Logic Controller PLC?

PLC is a device, which is used to control a machine or process as per the human control sequence.
A PLC monitors inputs, makes decisions based on its program, and controls outputs to automate a process
or machine.

Advantages

• Smaller physical size than hard-wire solutions

• Easier and faster to make changes
• PLCs have integrated diagnostics and override functions
• Diagnostics are centrally available
• Applications can be immediately documented
• Applications can be duplicated faster and less expensively
PROCESSOR MEMORY ORGANIZATION
The memory of a PLC is organized by types.

The memory space can be divided into two broad categories:

 Program and Data Memory:
Advanced ladder logic functins allow controllers to perform calculatins, make decisions and do
other complex tasks. Timers and counters are examples of ladder logic functions. They are more comples than basic
inputs contacts and output coils and relay heavily upon data stored in the memory of the PLC.

PROGRAM FILES:

The user program will account for most of the memory of a PLC system.
Program files contain the logic controlling machine operation.
This logic consistes of instructions that are programmed in a ladder logic format.

DATA FILES:

The data file protion of memory stores input and output status, processor status, the status of various bits and
numerical data.

INPUT TABLE FILE OPERATION:

 Processor continually reads current input status and updates input image table file.

OUTPUT TABLE FILE OPERATION:

Processor continually activates or deactivates ouput status according to output image table file status

PROGRAM SCAN:
During each operating cycle, the processor reads all inputs, takes these values, and energizes or de-energizes
the outputs according to the user program. This process is known as a scan. Because the inputs can change at any
time, the PLC must carry on this process continuously.
 1. I/O scan – records status data of input devices. Energizes output devices that have their associated status
bits set to ON (1)
2. Program scan – instruction are executed sequentially.

SCAN PROCESS:
The scan time indicates how fast the controller can react to changes in inputs. Scan times vary with computer
model and program content, and length. If a controller has to react to an input signal that changes states twice during
the scan time, it is possible that the PLC will never be able to detect this change.
 When the inputs is closed, the input module senses a voltage and an ON condition (1) is entered into the input
table bit ‘0012’.

During the program scan the processor sets instructins ‘0012’ and ‘506’ to ON(1).
 The processor turns light output ‘506’ ON during the next I/O scan.

KEYENCE

ADDRESS:

INPUTS:
0000 to 0015
0100 to 0115
0200 to 0215
0300 to 0315
0400 to 0415

OUTPUTS:
0500 to 0515
0600 to 0615
0700 to 0715
0800 to 0815
0900 to 0915

INTERNAL MEMORY BIT:

1000 to 1015
Upto
1900 to 1915

TIMERS:
TMR<add> space #<time> (0.1sec)
TMH<add> space #<time> (0.01sec)
TMS<add> space #<time> (0.001sec)

COUNTERS:
Up counter: C<add> space #<number of count>space<internal bit>
Up/Dwn counter: C<add>space#<number of count>
PROCEDURE FOR PROGRAMMING:
 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

1. Edit command/Lable
2. Edit line command
3. Show/Hide command
4. Jump to specified line/step
5. Find
6. Replace operand
7. Usage information
8. Edit list
9. compail
10. Show compilation error
11. Transfer to PLC
12. Read from PLC
13. Plc monitor
14. Simulator
15. Display mode
16. Description of operation

1 2 3 4 5 6 7 8 9 10

1. N.O. contact OR input

2. NC contact OR input
3. NO contact input
4. NC contact input
5. Output coil
6. NC output coil
7. Input vertical connection line
8. Delete vertical connection line
9. Input Horizontal connection line
 10. Delete Horizontal connection line

BASIC PROGRAMMES:

--| |-- NORMALY OPEN CONTACT

--| / |-- NORMALY CLOSED CONTACT

--( )-- COIL

EX: 1
When the switch (SW) is ON, the LOAD should ON (Rung 0001)
When the switch (SW) is OFF, the LOAD should ON (Rung 0002

Note: The all programming sequence should complete with ‘END’ AND ‘ENDH’.

LADDER LOGICS FOR DIGITAL GATES:

OR :
I1 I2 L
0 0 0
0 1 1
1 0 1
1 1 1

AND:
I1 I2 L
 0 0 0
0 1 0
1 0 0
1 1 1

NOR:
I1 I2 L
0 0 1
0 1 0
1 0 0
1 1 0

NAND:
I1 I2 L
0 0 1
0 1 1
1 0 1
1 1 0

EX-OR: EX-NOR:
I1 I2 L
0 0 1
0 1 1
1 0 1
 1 1 0 I1 I2 L
0 0 1
0 1 1
1 0 1
1 1 0

SWITCH CONTACTS:

EX 1: SW1= 0000, SW2= 0001, LD1 = 500, LD2 = 501

SW1 SW2 LD1 LD2

1 0 1 0
1 1 0 1

EX 2:
SW1 SW2 SW3 LD1 LD2 LD3
0 1 1 1 0 0
1 0 0 0 1 0
1 1 1 0 0 1
Document By
SANTOSH BHARADWAJ REDDY
Email: help@matlabcodes.com
Engineeringpapers.blogspot.com
More Papers and Presentations available on above site